Zero Defects using Layered Process Audits
Seminar Content
This two day performance packed workshop has you walk away with an action plan designed
to reduce Scrap, reduce Warranty Returns generated by manufacturing errors, and
improve First Time Through Capability. You will learn the DCX and General Motors
QSB Layered Process Audit requirements and you will create the necessary audit checklists
to support your Layered Process Audit Program. This workshop supports selected TS
16949:2002 and Customer Specific Requirements. This workshop is designed to enhance
your current Layered Process Audit Program by conducting Manufacturing Process Reviews
with your hourly work groups.
Who Should Attend
Quality Managers, Quality Supervisors, Quality Engineers, Manufacturing Engineers,
Production Supervisors, Production Leaders, Quality Technicians, Maintenance Technicians,
anyone responsible for making quality improvements.
Prerequisites
Basic understanding of process documentation (process flow diagram, PFMEA, control
plan).
Seminar Materials
Each participant will receive a seminar manual.
Seminar Goals
- You will conduct a Manufacturing Process Review of your process documentation including
your Process Flow Diagram, PFMEA, Control Plan and Work Instructions of your lowest
performing manufacturing cell(s).
- You will learn how to utilize the Error-Proofing Worksheet to provide a business
case to sell your recommended improvement actions.
- You will gain the understanding of DCX and General Motors QSB Layered Process Audit
requirements.
- You will create process and error-proofing checklists tied to your Layered Process
Audit Program.
- You will create a Walk-away Action Plan that sends you back to your plant with keys-in-hand
to drive your plant's quality improvements.
Seminar Outline
Day One
- What is a Layered Process Audit
- LPA Requirements and Recommendations
- Developing the LPA Plan
- Introduction to Process Review
- Process Review Team Dynamics
- Step 1: Process Flow Diagram
- What is Zero Quality Control?
- Step 2: Potential Failure Mode & Effects Analysis
- Error-Proofing Worksheet Overview
- Step 3: Reviewing & Revising the Control Plan
- Last Step: Work Instruction Overview
Day Two
- Review and Update Process Control Documentation
- Reporting and Managing the LPA Process
- Reviewing and Approving the LPA Plan
- Implementing the LPA Plan
- Maintaining the LPA
- LPA Best Practices
- Creating your Walk-away Action Plan
Course Sequence: MPR&LPA
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About Automotive / Production
Core Tools
APQP or Advanced Product Quality Planning is a structured method of defining & establishing
the steps necessary to ensure that a product satisfies the customer. Effective product
quality planning depends on a companys top managements commitment to the effort
required in meeting customer specifications.
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